Protective helmet with flush pivoting ear cups

ABSTRACT

A helmet includes a shell with an impact resistant exterior surface formed by an upper shell and a rear shell. The upper shell is shaped to protect a top portion of a wearer&#39;s head, the rear shell shaped to protect an occipital portion of the wearer&#39;s head. A headset assembly, attached to the shell, includes dual ear cups rotatable about an axis that is above the wearer&#39;s ears when the helmet is worn. The ear cups have at least the following positions: an extended position to cover the wearer&#39;s ears, and a retracted position substantially abutting both upper and rear shell to the rear of the wearer&#39;s ears. The ear cups are shaped so that they form a surface substantially flush with the exterior surface while the ear cups are in the retracted position.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to safety helmets. More particularly, theinvention concerns a helmet with ear cups that pivot into a positionthat is flush with the helmet, generally above and behind the wearer'sears.

2. Description of the Related Art

Today, there is a vast array of safety equipment available to workers.Steel-toed boots protect the feet from heavy weights or impact. Fire andheat resistant clothing helps protect the body against flame. Eyegoggles and face shields ward off debris and bright lights to protectthe eyes.

Probably one of the most common items of safety equipment is a helmet or“hard hat.” These are frequently used by construction workers, buildinginspectors, shipbuilders, factory workers, and others. However,conventional hard hats typically leave the wearer's ears exposed andvulnerable to impact damage. Of course, some people use ear plugs toprotect their hearing, but this still leaves their ears unprotected frompossible impact. Other people might use aftermarket ear muffs to protectagainst hearing loss, and this might provide some incidental protectionagainst impact injury to the ears. However, aftermarket ear muffs can bedifficult to wear with a conventional hard hat. There are some productswith integrated hard hat and ear muffs, but these typically protrudefrom the helmet in some direction, and necessitate an irregular outersurface of the helmet. Therefore, they are vulnerable to snagging onwiring, insulation, vehicle interior, brush, and other features of thewearer's work environment.

Thus, when selecting a safety helmet and ear protection there are manydifferent tradeoffs. Further complicating this, certain users might wishto listen to audio signals while using a safety helmet. Yet, finding anaudio system that is compatible with the helmet and ear protection canbe difficult or impossible.

Consequently, known safety helmets are not completely adequate for someapplications due to certain unsolved problems.

SUMMARY OF THE INVENTION

A helmet includes a shell with an impact resistant exterior surfaceformed by an upper shell and a rear shell. The upper shell is shaped toprotect a top portion of a wearer's head, the rear shell shaped toprotect an occipital portion of the wearer's head. A headset assembly,attached to the shell, includes dual ear cups rotatable about an axisthat is above the wearer's ears when the helmet is worn. The ear cupshave at least the following positions: an extended position to cover thewearer's ears, and a retracted position substantially abutting bothupper and rear shell aft of the wearer's ears. The ear cups are shapedso that they form a surface substantially flush with the exteriorsurface while the ear cups are in the retracted position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a right side plan view of a safety helmet.

FIG. 2 is a left side plan view of the safety helmet.

FIGS. 3A-3B are a rear views of the safety helmet.

FIG. 4 is an exploded top perspective view of the safety helmet.

FIG. 5A is a partial, top perspective view of the safety helmet.

FIG. 5B is a partial, bottom oblique view of the safety helmet.

FIG. 6 is a perspective view of a headband assembly.

FIG. 7 is an exploded view of a headset assembly.

FIGS. 8A-8B are perspective views of an eye shield guide and eye shieldguide, respectively.

FIG. 9 is a perspective view of a rear shell and lens.

FIG. 10 is an underside perspective view of an electronics module.

DETAILED DESCRIPTION

The nature, objectives, and advantages of the invention will become moreapparent to those skilled in the art after considering the followingdetailed description in connection with the accompanying drawings.

Hardware Components & Interconnections

Overall Structure

One aspect of the present disclosure concerns a safety helmet. Althoughthe safety helmet may be embodied by various hardware components andinterconnections, FIG. 1 shows one specific example in the form ofhelmet 100.

Broadly, the helmet 100 comprises a safety helmet with ear cups thatpivot between an extended position and a retracted position that isflush with the helmet, generally above (and also behind) the person'sears. Although not part of the helmet 100, a wearer 150 is shown forreference and perspective.

The helmet 100 includes a front end 102 and a rear end 104. One part ofthe helmet is a rigid upper shell 105 to protect the wear's head fromimpact injury. The upper shell 150 is made of a suitable material forthis purpose, such as polycarbonate or another suitable reinforced ornon-reinforced material.

Within the upper shell 105 are defined a number of vents 124, which inthe illustrated example comprise aerodynamic channels with aperturesleading to the interior of the helmet 100. The vents 124 permit airexchange between the wearer's head and outside the helmet without takingrain in.

The helmet 100 is shaped to form a visor 106, which protrudes wellforward of the wearer's face. The visor 106 affords some protection ofthe wearer's face from sun, rain, and falling debris. Integral with alower side of the visor 106 is an arc-shaped front lens 108, whichprotects a multiple beam light (not shown in this view) such as an LEDarray. FIG. 1 reveals a portion of an eye shield 107 (in retractedposition). The shield 107 is illustrated and described in greater detailbelow.

At the rear 104 of the helmet 100, there is a rear shell 110 and acurved rear lens 114. Within the rear shell 110, there is an electricalconnector (not visible in FIG. 1) for attaching electronic equipment ofthe helmet 100 to various off-helmet electrical equipment. Components atthe rear 104 of the helmet are described in greater detail below.

The helmet 100 also includes ear cups, one 116 b of which is visible inthe view of FIG. 1. The ear cups pivot about respective axes, such asthe axis 120 of the ear cup 116 b. The ear cups are held in a retractedposition, to the rear of the wearer's ears (e.g., 152) by one of variousmechanisms described below. In the illustrated example, there is afriction fit between the ear cup 116 b and an engaging feature 118 of aframe (not shown). The frame is illustrated and discussed in greaterdetail below. In their retracted position, the ear cups aresubstantially flush with the upper/rear shells 105/110, and moreparticularly, they present a surface that is substantially continuouswith the arc and shape of the rear shell 110 and upper shell 105. Byminimizing any protrusion from the helmet, the ear cups present acontiguous part of the helmet when retracted.

FIG. 2 shows the helmet 100 from the wearer's left side. This viewdemonstrates some of the helmet 100's movable parts. Namely, the eyeshield 107 and an ear cup 116 a are shown in their respective, extendedpositions.

FIGS. 3A-3B show the helmet 100 in rear view, in two differentconfigurations. In one configuration (302, FIG. 3A), ear cups 116 a-116b are extended. In another configuration (304, FIG. 3B), the ear cups116 a-116 b are retracted. Both configurations 302-304 illustrate therear 104 of the helmet, including features such as the rear lens 114 andrear shell 110.

FIG. 4 shows an exploded view of the helmet 100 to better illustrate theindividual pieces' shapes and interconnections. Optionally, the helmet100 includes vent plugs 412. In one example, the vent plugs 412 includeapertures (not shown) that are pressed over studs (not shown) protrudingfrom the shell 105's inner surface (i.e., the surface toward thewearer). In this example, the vent plugs are secured in place withTinnerman clips. Of course, other means of attachment may be employedsuch as shape fit, fasteners, clips, glue, press fit, screws, rivets,etc. Each vent plug 412 comprises an elastomeric member with protrusionsshaped to fit inside corresponding holes of the vents 124. While thehelmet 100 is not being worn, the wearer can insert/remove the ventplugs 412 into/from the vents 124 by bendably manipulating the plugs412.

Beneath the shell 105 is a frame 408. The frame 408 serves as a commonattachment point for the upper shell 105, rear shell 110, rear lens 114,front lens 108, and other components described below.

A number of additional components are coupled to the frame 408. One suchcomponent is the connector 112. The connector 112 comprises anelectrical coupling for electrically attaching helmet electronics(described below) to off-helmet electrical equipment. In one example,the connector is a six position IEEE 1394 receptacle such as Molex part53984-0611. In the illustrated embodiment, the connector 112 is mountedto a printed circuit board (PCB), which is attached to the frame 408.

The connector 112 is coupled to other electrical components aboard thehelmet 100, as described in greater detail below. Some of thesecomponents include an electronics module and headset assembly, and thesemay be electrically coupled to the connector 112 by one or more wiringharnesses, electrical buses, PCB traces, wires, Bluetooth or otherwireless links, etc. The connector 112 may be removably engaged withanother connector (not shown), electrically attached to variousoff-helmet components. Some examples of these off-helmet componentsinclude a listen-only audio source such as a flash-memory based musicplayer (such as MP3, iPod, etc.), AM/FM or satellite radio, CD player,etc. Another example is a two-way transceiver, such as a wireless phone,two-way radio, etc. As still another example, off-helmet components mayinclude an antenna, pack of one or more rechargeable or disposablebatteries, etc. In the illustrated example, the connector 112 iscompatible with a six position IEEE 1394 plug (not shown) such as a Tycopart 787950-1. This female plug is compatible with a male counterpartattached via cabling (not shown) to the off-helmet electronics. At aremote end of this cabling, there may be one or more 2.5 mm jacks tointerface with audio equipment, cell phones, etc.

Another component attached to the frame 408 is the electronics module406. Among other components, the module 406 includes a source of lightthat projects through the front lens 108 when the module 406 is mountedto the frame 408. Thus, in the finished helmet 100, the module 406 andlens 108 are built into the visor 106 of FIG. 1. The module 406 ismounted to the top side of the frame 408, as viewed in FIG. 4.

Another component, attached to the frame 408, is an eye shield guide402. The guide 402 provides a base for slidable movement of the eyeshield 107, defines full up and down travel, and removably secures theshield 107 in a user selected position. The guide 402 and its attachmentto the frame 408 are described in greater detail below.

Another component, attached to the frame 408 is a headset assembly 430.Primary components of the headset assembly are the ear cups 116 a-116 band the band 413, to which the ear cups 116 a-116 b are mounted. Theassembly 430 and its attachment to the upper shell 105 are describedbelow.

Still another component of the helmet 100 is the headband assembly 414.The assembly 414 provides an adjustable harness to provide a snug fit tothe wearer's head, which supports the helmet 100 during use. Theassembly 414 mounts to the frame 408 by four supports 416-419. Theassembly 414 and its attachment to the frame 408 are discussed below.

FIGS. 5A-5B illustrate some of the components of FIG. 4 in assembledform. Namely, FIG. 5A shows a top perspective view of the frame 408,headband assembly 414, supports 416-419, eye shield guide 402 (with eyeshield 107 removed), and electronics module 406. FIG. 5B shows a bottomoblique view of the helmet 100, where the following components arevisible: the frame 408, headband assembly 414, lens 108, guide 402, eyeshield 107, support 416, ear cups 116 a-116 b, rear shell 110, ventplugs 412, connector 112, and upper shell 105.

Headband Assembly

FIG. 6 shows the headband assembly 414 in greater detail. As mentionedabove, the headband assembly 414 provides an adjustable harness so thatthe wearer's head can comfortable and securely support the helmet 100.In one example, the assembly 414 includes a headband base 602 coupled tocrisscrossing straps 610, 612. The straps 610, 612, in one example,comprise nylon webbing. The base 602 includes mechanism 614 to adjustthe base to fit different head sizes.

In the illustrated example, the headband assembly 414 is attached to thebase 408 at the supports 416-419. More particularly, the supports416-419 are attached by fasteners, clips, glue, press fit, screws,rivets, detent or other shape fit, etc. The headset assembly 430attaches to the shell 105 as discussed above. The base 408 attaches tothe shell 105 by fasteners, clips, ultrasonic bonding, glue, press fit,screws, rivets, detent or other shape fit, etc. Thus, in the finalconstruction, the headset assembly 430 is positioned over the headbandassembly 414, permitting the assembly 414 to comfortably direct theweight of the helmet 100 upon the wearer's head.

Headset Assembly

FIG. 7 shows the headset assembly 430 in greater detail. Broadly, theassembly 430 includes the ear cups 116 a-116 b, which pivotably attachto the band 413. The band 413 includes studs 704 about which the earcups 116 a-116 b are free to rotate, as discussed below. In one example,the band 413 is made of spring steel, and the studs 704 include Press-instuds such as PEM part THFS-632-6. The band 413 also includes holes 724for use in attaching the band 413 to the upper shell 105. For example,the band 413 may be screwed or riveted to the shell 105 via holes 724.In a different example, the holes 724 may receive barbed studs (notshown) projecting from the shell 105, in order to secure the band 413 tothe shell 105. Of course, other arrangements may be used such asfasteners, clips, glue, press fit, shape fit, etc.

Each ear cup is comprised of an ear pad 710, inner shell 712, acousticfoam 714, and outer shell 716. The shells 712, 716 comprise plastic oranother material providing suitable protective strength and lightweight. In one example, the shells 712, 716 are bonded to each otherusing ultrasonic welding, solvent bond, epoxy, or other permanent seal.In one example, the ear cushion 710 comprises water impenetrablematerial such as GORE-TEX® material surrounding padding of neoprenefoam. In another example, the ear cushions 710 are gel or foam filledplastic or another durable yet soft material to provide cushioningbetween the wearer's head and the assembly 430.

Each inner shell 712 includes a pivot housing 723 to permit freerotation of the respective ear cup about an axis 722 through the pivothousing 723. In one example, each pivot housing 723 is implemented by adrilled or tooled or vacuum molded hole the shell 712. A stud 704protrudes through each such hole, enabling the ear cup can to pivotabout this hole. The ear cups 116 a-116 b are held in place by fasteners706, such as nuts with spring steel washers, and the fasteners 706 arecosmetically disguised by caps 708. As an alternative, the pivothousings 723 may be implemented by other arrangements such as bearings,bushings, axles, etc. Furthermore, instead of permitting free rotationof the ear cups 116 a-116 b about their respective studs 704, the pivothousings 723 and/or studs 704 may be defined to provide rotation underfriction, ratcheting movement, detent holding ear cups in position untilforcibly overcome, etc.

Each inner shell 712 further includes a tab 720 designed to interactwith a corresponding engaging feature 118 of the frame 408, which ismost clearly shown in FIGS. 1, 2, and 4A. In this example, the point ofrotation of the ear cups 116 a-116 b is defined relative the frame 408so that increasing movement of the ear cups 116 a-116 b into theirstowed position places the tabs 720 into increasingly firm contact withtheir respective engaging features 118. This holds the ear cups 116a-116 b firmly in place by friction between the tabs 720 and engagingfeatures 118. Further force applied to the ear cups 116 a-116 b in thisdirection more firmly engages the ear cups with the frame.Alternatively, the helmet 100 may employ other means to hold the earcups 116 a-116 b in place, such as springs, snaps, hooks, clips,magnets, etc.

The foam 714 comprises acoustically absorbent material such as thattypically used in conventional and industrial headsets. The outer shell716 includes a speaker assembly 718 electrically coupled to theconnector 112. One example of the speakers is a circumaural typespeaker.

Eve Shield and Guide

FIG. 8A-8B highlight the guide 402 and eye shield 107, respectively. Inone embodiment, the shield 107 is made of a clear or intentionallytinted material that meets or exceeds OSHA, UL, and/or CSA requirementsfor safety glasses. For example, the shield 107 may be made ofpolycarbonate, acrylic, or another suitable material. The guide 402 ismade of a material suitable to provide self-lubrication e.g. nylons andothers.

Although the shield 107 and guide 402 are shown separately, the shieldrides in a path defined and limited by the guide 402. When coupled tothe guide 402, the shield 107 is slidable in generally upward anddownward movements, allowing the wearer to retract and extend the shield(respectively).

The shield 107 includes a number of features that help establish andlimit its position with respect to the rest of the helmet 100. In thisrespect, the shield 107 includes down catches 810. Each catch 810includes a protrusion that engages a corresponding feature of the guide402 to stop extension of the shield 107. Positioning notches 812 aredefined in the shield 812 to engage a corresponding pawl of the guide402 and thereby hold the shield 107 one of these positions underadjustment by the wearer. Channels 814 defined in the shield 107 engagecorresponding features of the guide 402 to help stop retraction of theshield 107.

The guide 402 includes foldover flaps 808 defining slide slots 809 thatreceive and accommodate the shield 107. Up-stops 802 stop retraction ofthe shield 107 by engaging the channels 814. The stops 802 includeprotrusions that are biased toward the shield 107 by their size,position, and the natural springiness of the guide 402 material.Pedestals 804 are provided for mounting of the guide 402 to the frame408 by barbed studs, fasteners, clips, glue, press fit, screws, rivets,detent or other shape fit, etc. A pawl 806 engages with the positioningnotches 812 to hold the shield 107 in place, or releasably permit theextension or retraction of the shield 107 when the wearer appliessufficient force to slide the shield 107 and thereby disengage andreengage the pawl 806 from the notches 812 one at a time. Notches 807are engaged by the down catches 810 to stop extension of the shield 107.Alternatively, the notches 807 may be omitted, with the upper edge ofthe guide 402 serving to engage the down catches 810, albeit at anearlier point than the notches 807 would, and thereby not permitting asmuch down travel.

Rear Panel & Lens

FIG. 9 shows the rear shell 110 and lens 114 in greater detail. In therear shell, a notch 902 is defined to accommodate the connector 112,which is attached to the frame 408 as shown above. Aligners 910 permitthe shell 110 to be accurately positioned with respect to the frame 408.As shown, each of the aligners 910 is a base with a hole definedtherein. Mounting to the frame 408 occurs by the aligner hole's receiptof a screw, rivet, barbed stud, or other fastener. Alternatively,another means of securing may be used such as glue, ultrasonic bonding,clips, etc.

The shell 110 bears attachment pegs 904 shaped to engage correspondingholes 906 in the rear lens 114 and thereby secure the lens relative tothe shell 110. The shell 110 and lens 114 may be attached by a press fitbetween the pegs 904 and holes 906 and/or additional means such asultrasonic welding, solvent bond, epoxy, etc. Along these lines, thelens 114 includes knobs 908 to affix the lens 114 with respect to theframe 408.

A number of rear-facing light sources (not shown) may be attached to theframe 408 at a suitable position to be aligned with the lens 114. Forexample, four LEDs of type T1 may be used. Or, instead of multiple lightsources, a single light may be used with beam splitters, lenses, orother modification. These light sources serve a safety function, to makethe wearer more visible to people behind him/her. Optionally, therear-facing light sources may be red in color, or use a blinkingpattern. The light sources receive power from the electronics module 406via one or more wiring harnesses, electrical buses, PCB traces, wires,Bluetooth or other wireless links, etc.

As an alternative to the rear shell 110 and lens 114 that are separatefrom the upper shell 105 as illustrated, these features may be integralwith the upper shell 105, thereby forming a larger, contiguous combinedupper/rear shell.

Electronics Module

FIG. 10 shows the electronics module 406 in greater detail. As mentionedabove, the electronics module 406 includes a source of light thatprojects through the front lens 108 when the module 406 is mounted tothe frame 408. In one example, the module 406 may be mounted to theframe 408 by fasteners, clips, glue, press fit, screws, rivets, detentor other shape fit, etc. In the finished helmet 100, the module 406 andlens 108 are built into the visor 106 of FIG. 1.

One example of the module 406 includes an array of LEDs 1002 mounted toa printed circuit board 1003. In the illustrated example, six white LEDsof type T1-3/4 may be used. The LEDs 1002 may be aimed in the samedirection (as shown), or at various angles to enhance the overallpresentation of light around the wearer's workspace. Optionally, theLEDs 1002 may even be distributed to provide peripheral lighting inaddition to straight-ahead illumination respective to the wearer's faceand normal field of view. Instead of multiple separate beams (as shown),the same or similar effect may be accomplished with beam splitters,lenses, etc.

The module 406 may include further electronics. In one example, themodule 406 includes brow microphones 1004 enabling the wearer of thehelmet 100 to conduct hands free communications utilizing an off-helmetaudio module coupled to the connector 112. As an example, 6 mmdirectional microphones may be used to effectively define a “beam” ofheightened sound reception aimed at the site of an average wearer'smouth. The microphones 1004 may include a moisture barrier, such asGORE-TEX® or a similar material.

As shown, the module 406 also includes a photo sensor 1008, such as aPerkin Elmer part A9060. Optionally, circuitry of the board 1003 mayautomatically activate the LEDs 1002 and/or the rear light when thesensor 1008 finds that ambient light is less than a given threshold.

In order to provide more intelligent functionality to the helmet 100,the module 406 may also accommodate various circuitry in the form ofdiscrete circuit elements, integrated circuits, ASICs, and the like. Forexample, the module 406 may include Fortemedia brand FM1072LP chips inorder to aid processing of audio signals received at the microphones1004, prevent feedback between the microphone and speakers, etc. As afurther example, the module 406 may include circuitry to convert mobilephone signals to a speakerphone and headset function for send andreceive, and to provide a stereo amplifier for the speakers 718.

The module 406 further includes hand-operated dual switches 1006, suchas E-Switch part EG2305A. The dual switches 1006 may be attached topermit the wearer to selectively deactivate the LEDs 1002, rear light,microphones 1004, and/or other electronic equipment.

Optionally, through the switches 1006 or on-board circuitry, the module406 may automatically or manually adjust the volume of the ear cupspeakers. For instance, the module 406 may utilize a softer volume whilethe ear cups are extended, and use a louder “speakerphone” volume whilethe ear cups are retracted. As a more particular example of theautomatic embodiment, the ear cups 116 a-116 b may actuate a switchmounted to the frame 408 or other structure, where this switch isactivated by a raised feature of one or both ear cups 116 a-116 b closeto the pivot point when ear cups are extended. Without any intendedlimitation, some specific examples of this raised feature include one orboth of the tabs 730-731 (FIG. 7). In this example, the switch isde-activated when the ear cups are retracted, and activated when the earcups are extended. In one example, the switch connects the speakers todifferent amplifier circuitry depending upon whether the switch isactivated or deactivated. In another example, the switch provides aninput signal to a controller of the electronics module 406, whichregulates volume accordingly.

Helmet Features

As described above, the helmet 100 offers a variety of useful featuresin one package. The helmet 100 provides MP3, CD player, radio, cellphone, two-way radio, or other audio to the wearer by virtue of thespeaker assemblies 718 in ear cups 116 a-116 b. And, with thedirectional brow microphones 1004, the helmet 100 enables the wearer toconduct mobile, hands free speech through an attached, off-helmetwireless phone or two-way radio transceiver. Audio signals are conveyedto/from remote electronics by the connector 112 and appropriate cabling(not shown). Moreover, the wearer's eyes are protected by theretractable eye shield 107. To fully illuminate the wearer's workspacewith minimal intrusion, the front-facing light assembly 1002 is providedinternal to the visor 106 and protected by a brow lens 108 that is flushwith the visor 106. For added safety, the rear-facing light makes surethat the helmet is visible from behind. Furthermore, the ear cups 116a-116 b are particularly convenient because they are retractable.Moreover, they are unlikely to catch on wiring, insulation, vehicleinterior, brush, or other features of the wearer's work environment,since the ear cups 116 a-116 b when retracted are flush with helmet'sexterior surface, namely, the upper shell 105 and the rear shell 110.Despite the collective benefit of these features, the helmet stillprovides significant utility if one or more of these are omitted.

Helmet Operation

In preparation for use of the helmet 100, the wearer uses the mechanism614 to adjust the headband base 602. The wearer also couples theconnector 112 to the desired electrical equipment, such as one-way ortwo-way audio equipment, battery pack, etc. When the wearer dons thehelmet 100, the axis 722/120 is generally just above the wearer's ears.Thus, the ear cups 116 a-116 b when retracted rest above and generallybehind the wearer's ears, flush with the outer surface of the shells105, 110. The ear cups 116 a-116 b are secured in the stowed position byfriction between the tab 720 of the headset assembly 430 and theengaging feature 118 of the frame 408. In this position, recognizingthat the ear cups are stowed, the helmet 100 may automatically providean increased “speaker phone” volume to the ear cup speakers.

When the helmet 100 is being worn, the wearer operates the switches 1006to configure electrical features such as the front lights, rear lights,audio on/off, microphone mute, and the like. To extend the ear cups 116a-116 b, the wearer applies downward force to the ear cups 116 a-116 b,which disengages the tabs 720 from the engaging features 118. The earcups 116 a-116 b then hang in a free pivoting mode, or they may be heldin place by a feature (not shown) such as a catch, detent, ratchet,clasp, etc. In this position, recognizing that the ear cups areextended, the helmet 100 may automatically select a decreased volume forear cup speakers.

To retract the ear cups 116 a-116 b again, the wearer pivots the earcups rearward, ultimately engaging the tabs 720 with the features 118.Greater force applied to the ear cups in this way more snugly engagesthem with the frame 408 in tighter fit.

Other Embodiments

While the foregoing disclosure shows a number of illustrativeembodiments, it will be apparent to those skilled in the art thatvarious changes and modifications can be made herein without departingfrom the scope of the invention as defined by the appended claims.Accordingly, the disclosed embodiment are representative of the subjectmatter which is broadly contemplated by the present invention, and thescope of the present invention fully encompasses other embodiments whichmay become obvious to those skilled in the art, and that the scope ofthe present invention is accordingly to be limited by nothing other thanthe appended claims.

All structural and functional equivalents to the elements of theabove-described embodiments that are known or later come to be known tothose of ordinary skill in the art are expressly incorporated herein byreference and are intended to be encompassed by the present claims.Moreover, it is not necessary for a device or method to address each andevery problem sought to be solved by the present invention, for it to beencompassed by the present claims. Furthermore, no element, component,or method step in the present disclosure is intended to be dedicated tothe public regardless of whether the element, component, or method stepis explicitly recited in the claims. No claim element herein is to beconstrued under the provisions of 35 USC 112, sixth paragraph, unlessthe element is expressly recited using the phrase “means for” or, in thecase of a method claim, the phrase “step for.”

Furthermore, although elements of the invention may be described orclaimed in the singular, reference to an element in the singular is notintended to mean “one and only one” unless explicitly so stated, butshall mean “one or more”. Additionally, ordinarily skilled artisans willrecognize that operational sequences must be set forth in some specificorder for the purpose of explanation and claiming, but the presentinvention contemplates various changes beyond such specific order.

The previous description of the disclosed embodiments is provided toenable any person skilled in the art to make or use the presentinvention. Various modifications to these embodiments will be readilyapparent to those skilled in the art, and the generic principles definedherein may be applied to other embodiments without departing from thespirit or scope of the invention. Thus, the present invention is notintended to be limited to the embodiments shown herein but is to beaccorded the widest scope consistent with the principles and novelfeatures disclosed herein.

1. A helmet, comprising: a shell comprising an impact resistant exteriorsurface formed by an upper shell and a rear shell, the upper shellshaped to protect a top portion of a wearer's head, the rear shellshaped to protect an occipital portion of the wearer's head; a headsetassembly attached to the shell, comprising: dual ear cups rotatableabout an axis that is above the wearer's ears when the helmet is worn,the ear cups having at least the following positions: an extendedposition to cover a wearer's ears, and a retracted positionsubstantially abutting both upper and rear shell aft of the wearer'sears; where the ear cups are shaped to form a surface substantiallyflush with the exterior surface while the ear cups are in the retractedposition.
 2. The helmet of claim 1, further comprising: an electricalconnector configured for detachable electrical connection to off-helmetelectronics; audio speakers installed in the ear cups, the speakersincluding signal inputs electrically coupled to the connector.
 3. Thehelmet of claim 1, further comprising: a first electrical connectorpositioned proximate the rear shell; a second electrical connector,detachably coupled to the first electrical connector, the secondelectrical connector electrically attached via one or more cables to oneor more electronic components located apart from the helmet; theelectronic components including one or more batteries and an audiosource; audio speakers installed in the ear cups, the speakers includingsignal inputs electrically coupled to the first connector.
 4. The helmetof claim 3, the shell includes a rear end proximate the rear shell and afront end opposite the rear end, and the front end includes a narrowedextension providing a visor; where the audio source includes a two-waytransceiver, and the helmet further includes one or more visor-mountedmicrophones including signal outputs electrically coupled to the firstconnector.
 5. The helmet of claim 1, where: the shell includes a rearend proximate the rear shell and a front end opposite the rear end, andthe front end of the shell includes a narrowed extension providing avisor; the helmet further includes: audio speakers located in the earcups, at least one hands-free microphone attached to the visor, at leastone connector to electrically couple to a transceiver, and one or morelinks connecting the connector with the microphone and the speakers. 6.The helmet of claim 1, where: the shell includes a rear end proximatethe rear shell and a front end opposite the rear end, and the front endincludes a narrowed extension providing a visor; the helmet furtherincludes a light assembly internal to the visor and protected by a browlens substantially flush with the visor.
 7. The helmet of claim 1,where: the shell includes a rear end proximate the rear shell and afront end opposite the rear end; the helmet further comprises an eyeshield adjacent the front end, the eye shield being slidably retractableupwardly into the helmet.
 8. The helmet of claim 1, further comprising:an internal frame coupled to the upper shell and rear shell; a headbandassembly coupled to the frame; an eye shield; a guide connected to theframe and defining one or more slide slots to receive the eye shield andpermit slidable retraction and extension of the eye shield relative tothe guide; where one of the eye shield and guide include includes a pawland the other of the eye shield and guide includes positioning notches,the pawl and notches positioned complimentarily to provide ratchetingadjustment of the eye shield in predefined positions affixed byengagement of the pawl and notches.
 9. The helmet of claim 1, furthercomprising: an internal frame coupled to the upper shell and rear shell;a headband assembly coupled to the frame; an eye shield; guide means forfacilitating slidable retraction and extension of the eye shieldrelative to the helmet; means for ratcheting adjustment of the eyeshield in predefined positions.
 10. The helmet of claim 1, where: theupper shell and rear shell are positioned to define a gap therebetween;the helmet further includes a rear-facing light assembly positioned toshine through the gap when illuminated, and a lens covering the gap andprotecting the rear-facing light assembly.
 11. The helmet of claim 1,further comprising: means for securing the ear cups in the retractedposition.
 12. The helmet of claim 1, further comprising: an internalframe coupled to the upper shell and rear shell; a headband assemblycoupled to the frame; where the ear cups are shaped to engage the framewhile in the retracted position, the engagement sufficient to removablysecure the ear cups in the retracted position.
 13. The helmet of claim1, further comprising: a switch, responsive to position of the ear cups,to provide a higher volume to speakers in the ear cups when the ear cupsare retracted and a lower volume to the speakers when the ear cups areextended.
 14. The helmet of claim 1, further comprising: means forproviding a higher volume at speakers in the ear cups when the ear cupsare retracted and a lower volume when the ear cups are extended.
 15. Thehelmet of claim 1, where: the shell includes a rear end proximate therear shell and a front end opposite the rear end, and the front end ofthe shell includes a narrowed extension providing a visor; the helmetfurther comprises: at least one hands-free microphone attached to thevisor; audio speakers installed in the ear cups; at least one connectorto electrically couple to a transceiver; one or more links coupling theconnector with the microphone and the speakers, adjacent the front end,an eye shield that is slidably retractable upwardly into the helmet, alight assembly internal to the visor and protected by a brow lenssubstantially flush with the visor.
 16. A helmet, comprising: a shellcomprising an impact resistant exterior surface to protect top andoccipital portions of a wearer's head; a headset assembly attached tothe shell, comprising: dual ear cups rotatable about an axis that issubstantially above the wearer's ears when the helmet is worn, the earcups having at least the following positions: an extended position tocover a wearer's ears, and a retracted position substantially abuttingboth upper and rear shell aft of the wearer's ears; where the ear cupsform a surface substantially flush with the exterior surface while theear cups are retracted.
 17. A helmet, comprising: a headband assembly toreceive a helmet wearer's head; a frame coupled to the headbandassembly; a shell comprising an impact resistant exterior surface formedby an upper shell and a rear shell separately coupled to the frame, theupper shell shaped to protect a top portion of a wearer's head, the rearshell shaped to protect an occipital portion of the wearer's lead; aheadset assembly attached to the shell, comprising: dual ear cupsrotatable about an axis that is substantially above the wearer's earswhen the headband assembly receives the wearer's head, the ear cupshaving at least the following positions: an extended position to cover awearer's ears, and a retracted position substantially abutting bothupper and rear shell aft of the wearer's ears; where the ear cups areshaped so that to form a surface substantially flush with the exteriorsurface while the ear cups are in the retracted position.